Insulation displacement connector
A conductive terminal for receiving a conductor is disclosed. The terminal includes a base and two resilient beams extending from the base. Generally distal the base, the beams define a mouth for receiving the conductor. The beams have facing inner edges which define a slot extending from the mouth. The beams define a generally egg-shaped aperture in an area extending between the slot and the base.
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This application is a CON of Ser. No. 09/030,564 filed Feb. 25, 1998 now U.S. Pat. No. 6,142,817, which claims the benefit of U.S. Provisional Application Ser. No. 60/040,079 filed Mar. 7, 1997.
BACKGROUNDInsulation Displacement Connectors (IDC) are a widely used connection technology in the communication industry. An IDC connector or clip performs two functions: severing or splitting plastic insulation surroundings a conductive wire to provide access to the conductive wire thereunder and frictionally engaging and/or compressing the conductive wire to provide electrical contact. In the design of an IDC clip, numerous variables must be considered in order to provide optimal clip design to achieve desired operating characteristics. As a general background, it is desirable to have an IDC clip which displaces the insulation, deforms the conductive wire and does not cut the conductive wire. Also, it is desirable to have an IDC clip which maintains a desired pressure on the deformed conductive wire and forms a contact area of a desired size. Further, it is desirable to provide stress distribution throughout the clip structure such that the conductive wire can be repeatedly terminated and disengaged therewith without the clip failing. Additionally, in the present communication industry, it is important to reduce the costs associated with the equipment. As such, the material cost and manufacturing costs associated with the IDC clip must be minimized.
Prior art IDC clips generally provide symmetric clip structures which function well but are not necessarily optimized. Examples of prior art IDC clips are provided in
A general object envisioned by the present invention is to provide a conductive terminal for receiving a wire conductor where the conductive terminal provides desirable stress distribution during engagement with the wire conductor.
Another object envisioned by the present invention is to provide a conductive terminal for receiving a wire conductor where the conductive terminal can be repeatedly terminated and disengaged with the wire conductor without the conductive terminal failing.
Yet another object envisioned by the present invention is to provide a conductive terminal for receiving a wire conductor where the conductive terminal has relatively low material cost and manufacturing costs associated therewith yet is reliable and can repeatably make termination without failure.
Briefly, and in accordance with the foregoing, the present invention provides a conductive terminal for receiving a conductor. The terminal includes a base and two resilient beams extending from the base. Generally distal the base, the beams define a mouth for receiving the conductor. The beams have facing inner edges which define a slot extending from the mouth. The beams define a generally egg-shaped aperture in an area between the slot and the base.
The organization and manner of the structure and function of the invention, together with the further objects and advantages thereof, may be understood by reference to the following description taken in connection with the accompanying drawings, wherein like reference numerals identify like elements, and in which:
While the present invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, an embodiment with the understanding that the present description is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to that as illustrated and described herein.
Shown in
Generally, when a conductor such as a conductive wire is inserted between the beams 22, 24, the IDC 20 preferably pierces or severs an outer insulating layer surrounding an inner conductor and frictionally engages or compresses the inner conductor to establish electrical contact therewith. The present invention provides a novel connector with optimized IDC 20 geometry and stress distribution under loading. The mechanical properties of the IDC 20 in accordance with the present invention facilitate reliable and repeatable termination for a predetermined range of insulated wire sizes. Also, the IDC 20 of the present invention is rather dimension insensitive such that it can be fabricated to small dimensions, if necessary, and still retain the mechanical benefits of the overall design.
With reference to
When a conductor such as a conductive wire is engaged with the IDC 20, the conductor is inserted through the mouth 34 into the slot 44 between the beams 22, 24. Insertion of a wire into an IDC generally is well known in the art such that the IDC will sever an insulating jacket of the wire and engage the conductive inner portion of the wire. As shown in
With further reference to the enlarged, partially fragmentary, front-elevational view of the IDC 20 as shown in
The aperture 26 is symmetrical about the central axis 58 which is coincident with the major axis of the egg-shaped aperture, and a line 59 perpendicular to the central axis is designated a minor axis of the egg-shaped aperture. The minor axis is drawn approximately through the widest dimension of the egg-shaped aperture but is otherwise located arbitrarily.
The term “egg-shaped” is an adjective and is defined as having an oval form, usually with one end larger than the other. See The Random House Dictionary of the English Language, 2nd Edition, unabridged, 1987. The Dictionary also defines as egg-shaped, terms such as “ovate”, “oval”, “oviform” and “ovoid”.
The aperture edge 62 has two generally edge halves 64, 66 which join at the base 32. Each edge half 64, 66 is defined by three different radii, shown herein by radial indicators 68, 70 and 72. In the interest of clarity in describing the invention, only the radial indicators associated with one edge half 64 of the edge 62 are shown and it is understood that the description of one half is representative of both edge halves 64, 66. The halves 64, 66 mirror each other and are symmetric about the central axis 58, and therefore so do the radii 68, 70 and 72 of each half 64 and 66 of the arcuate edge 62.
Edge half 64 is formed by three edge portions 74, 76 and 78, and half 66 is formed by three corresponding edge portions 80, 82 and 84. a first edge portion 74 of half 64 of the edge 62 is adjacent the slot 44 and is defined by a top radius 68 (Rtop in FIG. 4). The top radius 68 is sized and dimensioned to provide that the first edge portion 74 of half 64 is generally continuous and generally arcuate with the adjacent, second edge portion 76 of half 64. Likewise, the second edge portion 76 is defined by a mid-radius 70 (Rmid in
As shown, edge portion 74 of half 64 is essentially a mirror image of edge portion 80 of half 66, and edge portion 76 of half 64 is essentially a mirror image of edge portion 82 of half 66. The third edge portion 78 of half 64 is defined by a bottom radius 72 (Rbottom in
As mentioned above, edge half 64 of edge 62 is essentially a mirror image of the other edge half 66. Therefore, edge portion 80 is defined by a radius generally identical to that of radius 68 defining edge portion 74. Likewise, edge portion 82 is defined by a radius generally identical to that of radius 70 defining edge portion 76. Finally, edge portion 84 is defined by a radius generally identical to that of radius 72 defining edge portion 78.
The egg-shaped aperture 26 is defined by the top, mid and bottom radii 68, 70, 72 and an additional variable in the form of a height dimension 86 which, when combined with the radii 68, 70, 72, control the overall shape of the aperture 26. A relationship is defined by the present invention 20 such that the mid-radius 70 is greater than the top radius 68 which is greater than the bottom radius 72 or in other words, Rmid(70)>Rtop(68)>Rbottom(72). As seen in
-
- 0.05<Rtop(68)/Rmid(70)<0.28;
- 1.3<Rtop(68)/Rbottom(72)<4.3; and
- 0.1<Rtop(68)/height (86)<0.35.
As described, the arcuate edge 62 defining the aperture 26 is composed of three pairs of different radii 68, 70, 72 symmetrically arranged along about each beam 22, 24. This provides that the aperture 26 between the beams 22, 24 is generally symmetrical along about the central longitudinal or major axis 58 of the IDC 20 but is not symmetrical about the minor axis 59. As can be seen from the figures, the first edge portions 74, 80 are positioned along the aperture edge 62 opposite one another. Similarly, the second edge portions 76, 82 are positioned opposite each other along the edge 62 and the third edge portions 78, 84 are likewise positioned opposite each other.
The IDC 20 of the present invention has been verified through finite element analysis which indicates that the aperture 26 defined by arcuate portions 74, 76, 78 and 80, 82, 84 corresponding to the radii 68, 70, 72, respectively, is capable of handling heavy bending loads. The advantage of the geometry defined by the arcuate portions 74, 76, 78 and 80, 82, 84 over prior art IDC connectors is that the present invention minimizes stress concentration at the bottom area 88 of the aperture 26 where the beams 22, 24 join at the base 32. The IDC 20 of the present invention spreads out the bending load along the arcuate portions 74, 76, 78 and 80, 82, 84 to optimize stress distribution.
The aperture 26 of the IDC 20 has been specifically described herein with reference to the specific preferred radii and arcuate edges thereof. However, one skilled in the art may recognize other non-circular and egg-shaped apertures which accomplish a similar result (i.e. efficient stress distribution) of directing the stress concentration from any one specific area of the IDC. As a result, the present invention is not meant to be limited to the specific aperture 26 and arcuate edge 62 depicted and described herein, and the edge 62, and therefore the aperture 26 defined thereby, may take other shapes.
In prior art IDC structure, when a wire is engaged with the IDC, high bending stresses concentrate at the bottom portion of the aperture where the beams join each other. These high stresses cause the prior art IDCs to yield and fail to perform proper wire termination. When the prior art IDC yields at the corners and fails to complete a proper wire termination, the stress at other locations along the beams are typically well below the yield point of the material. As such, prior art IDC connectors do not optimize the mechanical properties of the IDC structure.
In contrast, the IDC 20 of the present invention optimizes stress distribution under loading and optimizes the mechanical properties of the IDC material and structure. As a result, the IDC connector 20 of the present invention is rather dimension insensitive and can be fabricated to be much smaller (for example, 50% smaller) than a comparable prior art IDC used to terminate the same, or even a smaller, range of wire sizes, using the same material for the IDC connector. As such, the present invention minimizes the size and material costs yet improves the reliability and repeatability of the IDC to make termination without failure. Consequently, the density of the IDC connectors can be increased within a given area while still being capable of terminating a broad range of wire sizes. As such a plurality of pairs of resilient beams 22, 24 can be produced extending from a common base 32. This would allow interconnectivity of the conductor connected with respective pairs of beams.
In contrast, with reference to
Another important consideration of the IDC structure 20 of the present invention is that while the insulation is cut, the material of the central conductor is not. Rather, the material of the conductor is deformed and displaced so as to provide greater contact surface area for making the conductive connection. Also, deformation and displacement of the conductor material prevents degrading the conductor strength. In contrast, the prior art tends to cut at least a portion of the conductor material and may not optimize the conductive connection between the IDC structure and the conductive wire.
While a preferred embodiment of the present invention is shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims. For example, the aperture 26 and edge 62 defining same may vary from that which is depicted and described herein. Therefore, the invention is not intended to be limited by the foregoing disclosure.
Claims
1. A conductive terminal for receiving a conductor, said terminal comprising:
- a base;
- a pair of resilient beams extending from said base, said beams defining a mouth at an end thereof generally distal said base for receiving the conductor, said beams having facing inner edges defining a slot extending from said mouth, said beams defining a generally egg-shaped aperture in an area extending between said slot and said base.
2. The terminal as recited in claim 1, said egg-shaped aperture defining a generally continuous arcuate aperture edge.
3. The terminal as recited in claim 1, said egg-shaped aperture being defined by an aperture edge extending along both beams and joining said beams at said base, said aperture edge being defined by a plurality of radii.
4. The terminal as recited in claim 3, said aperture edge being defined by three pairs of different radii symmetrically arranged along each beam.
5. The terminal as recited in claim 1, said egg-shaped aperture being symmetrical about a central longitudinal axis of said terminal.
6. The terminal as recited in claim 5, said central longitudinal axis dividing said egg-shaped aperture into two halves, each half of said egg-shaped aperture being defined by an arcuate edge along a corresponding one of said pair of beams, said arcuate edge being defined by a plurality of radii, wherein said radii defining said arcuate edge of each half of said egg-shaped aperture are symmetrical about said central longitudinal axis with respect to the radii defining said arcuate edge of the other half of said egg-shaped aperture.
7. The terminal as recited in claim 6, each half of said egg-shaped aperture being defined by a generally continuous arcuate edge being defined by at least three radii.
8. The terminal as recited in claim 7, each half of said egg-shaped aperture being defined by three arcuate edge portions forming said generally continuous arcuate aperture edge.
9. The terminal as recited in claim 1, said egg-shaped aperture being divided into two halves positioned on either side of said slot, each half of said egg-shaped aperture being defined by a first edge portion, a second edge portion and a third edge portion, said first edge portion positioned adjacent said slot and being defined by a first radius, said second edge portion positioned adjacent said first edge portion and being defined by a second radius, and said third edge portion positioned adjacent said second edge portion and being defined by a third radius.
10. The terminal as recited in claim 9, wherein said third radius is smaller than said first radius, and said first radius is smaller than said second radius.
11. The terminal as recited in claim 9, wherein said first edge portions of each half of said egg-shaped aperture oppose each other, said second edge portions of each half of said egg-shaped aperture oppose each other, and said third edge portions of each half of said egg-shaped aperture oppose each other.
12. The terminal as recited in claim 1, further comprising a plurality of said pairs of resilient beams extending from said base.
13. A terminal for receiving a conductor, said terminal comprising:
- a base; and
- two substantially parallel resilient cantilever beams extending from said base, said beams forming a mouth at an end thereof for receiving the conductor between said beams, a slot between said beam members extending from said mouth to an aperture, said aperture being non-symmetrical about an axis thereof, an upper portion thereof having a larger dimension that a lower portion thereof, said axis being perpendicular to a longitudinal axis of said terminal.
14. A terminal for receiving a conductor, said terminal comprising:
- a base; and
- two substantially parallel resilient cantilever beams extending from said base, said beams forming a mouth at an end thereof for receiving the conductor between said beams, a slot between said beams extending from said mouth to an aperture, said aperture being non-circular and being defined by a generally continuous arcuate aperture edge.
15. A terminal for receiving a conductor, said terminal comprising:
- a body, said body defining a mouth for receiving said conductor and a non-circular aperture communicating with said mouth, said non-circular aperture being defined by a generally continuous arcuate aperture edge comprising at least three arcuate edge portions, each of said three arcuate edge portions being defined by a corresponding radius.
16. A terminal for receiving a conductor, said terminal comprising:
- a body, said body defining an aperture, a mouth of said body communicating with said aperture, said aperture being non-circular and defined by an edge spaced at said mouth and connected distal said mouth, said edge being defined by a plurality of different radii.
17. A terminal for receiving a conductor, said terminal comprising:
- a body, said body defining an aperture, a mouth of said body communicating with said aperture, said aperture being non-circular and defined by two symmetrical edges which are spaced at said mouth and connected distal said mouth, each of said edges being defined by three different radii.
18. The terminal recited in claim 17, wherein said three different radii include a top radius, a middle radius and a bottom radius, said aperture being defined by the following radii ratios,
- 0.05<top radius/middle radius<0.28, and
- 1.3<top radius/bottom radius<4.3, and
- 0.1<top radius/height<0.35 in which the height is the dimension of the aperture measured from the upper most portion of the aperture to the lower most portion of the aperture.
19. An insulation displacement connector comprising:
- first and second beams joined at a base and extending away therefrom, each of said beams having a top edge;
- a slot formed between said beams extending away from the top edges of said beams toward said base, said slot being bordered by two oppositely disposed, generally parallel side edges, one of said side edges being a part of said first beam and the other of said side edges being a part of said second beam, said slot for receiving an electrical conductor and said beams for providing a force on said conductor normal thereto; and
- an aperture formed between said beams at the end of said slot, said slot opening into said aperture, said aperture extending from said slot to said base and being egg shaped with a larger end portion of said egg shaped aperture being nearest said slot and a smaller end portion of said egg-shaped aperture being nearest said base, said aperture being bordered by two curved edges, one of said curved edges being a portion of said first beam and the other of said curved edges being a portion of said second beam, each of said curved edges having a smooth transition through a plurality of radii and being joined together at said base at a location furthest from said top edges of said beams.
20. The apparatus as claimed in claim 19 wherein:
- said conductor causes stress in said beams, said stress being greatest in said beams at a location about mid-way along said aperture as it extends away from said slot and at a location along outer edges of said beams.
21. The apparatus as claimed in claim 20 wherein:
- said stress being greatest where said plurality of radii have their largest dimensions.
22. The apparatus as claimed in claim 19 wherein:
- said plurality of radii include larger and smaller dimensions, and the curved edges have radii with the larger dimensions disposed between the larger end portion and the smaller end portion of said egg shaped aperture.
23. The apparatus as claimed in claim 22 wherein:
- said conductor causes stress in said beams, said stress being greatest in said beams at a location about mid-way along said aperture as it extends away from said slot and at locations along outer edges of said beams.
24. The apparatus as claimed in claim 23 wherein:
- said stress being greatest where said curved edges have radii with their largest dimensions.
25. An insulation displacement connector comprising:
- first and second upstanding beams of conductive metal;
- said first and said second beams being separated by an electrical conductor receiving slot extending for a first vertical distance away from upper ends of said first and said second beams;
- said first and said second beams also being separated by an aperture, said aperture opening from said slot and extending for a second vertical distance away from said upper ends of said first and said second beams, and said aperture having top, middle and bottom portions and horizontally extending width dimensions therein; and
- said aperture having its largest horizontal width dimension in said top portion, a smaller horizontal width dimension in said middle portion relative to said horizontal width dimension of said top portion and a smallest horizontal width dimension in said bottom portion relative to said horizontal width dimensions of said top and said middle portions.
26. The apparatus as claimed in claim 25 wherein:
- said aperture is shaped to have a continuing reduction in the horizontal width dimensions in said vertical direction away from said upper ends of said first and said second beams and below said top portion.
27. The apparatus as claimed in claim 26 wherein:
- said slot is adapted to receive an insulated conductor, said conductor causing stress in said first and said second beams, said stress being at its maximum adjacent said middle portion of said aperture.
28. The apparatus as claimed in claim 27 wherein:
- said first and said second beams having inner and outer edges thereof, said maximum stress being located along said inner and said outer edges.
29. The apparatus as claimed in claim 28 wherein:
- said aperture is formed by a plurality of radii, where radii in said middle portion are larger than radii in said top and bottom portions.
30. The apparatus as claimed in claim 29 wherein:
- said first and said second vertical distances are about equal.
31. An insulation displacement connector comprising:
- an electrically conductive metal strip divided into two generally parallel beams, each beam having inner and outer edges;
- a slot formed between said beams along said inner edges, said slot extending from a top end of said strip for a first predetermined distance; and
- an aperture in communication with said slot and extending away from said slot for a second predetermined distance, said aperture opening to its largest width dimension near said slot and then smoothly tapering to smaller width dimensions in a direction away from said slot.
32. The apparatus as claimed in claim 31 wherein:
- said aperture has an egg shape in an elevational view.
33. The apparatus as claimed in claim 31 wherein:
- said slot is adapted to receive an insulated conductor where said conductor causes stress in said beams, said stress being greatest in said beams near said aperture about mid-way along said second predetermined distance and near said outer edges thereof.
34. The apparatus as claimed in claim 33 wherein:
- said stress near said outer edges being located at about the same vertical distance from said slot as said stress near said aperture.
35. The apparatus as claimed in claim 31 wherein:
- said aperture is comprised of a varying radii curve symmetrical about a central vertical axis where larger radii occur at a middle portion of said aperture along said second predetermined distance; and
- said slot is adapted to receive an insulated conductor where said conductor causes stress in said beams, said stress being greatest in said beams near said middle portion of said aperture and near said outer edges thereof.
36. The apparatus as claimed in claim 35 wherein:
- said stress also being greatest near said outer edges located about equal the vertical distance from said slot as is said middle portion of said aperture.
37. An insulation displacement connector comprising:
- a first beam having a length;
- a second beam having a length;
- a base connecting said first and said second beams;
- a slot formed between said first and said second beams extending for a portion of said lengths of said first and said second beams; and
- an egg shaped aperture formed between said first and said second beams extending from an end of said slot for another portion of said lengths of said first and said second beams wherein stress created by an electrical conductor being received by said slot is distributed in said first and said second beams so as to allow the connector to be reduced in size without a reduction in function.
38. The apparatus as claimed in claim 37 wherein:
- said stress is concentrated in said beams along the portions of the aperture having larger middle radii.
39. The apparatus as claimed in claim 37 wherein:
- said stress is minimized in said base where said beams are connected.
40. The apparatus as claimed in claim 37 wherein:
- said connector is reduced in size by about fifty percent.
41. The apparatus as claimed in claim 37 wherein:
- said connector accommodates a plurality of wire sizes in said slot.
42. The apparatus as claimed in claim 37 wherein:
- said stress is distributed to allow said connector to be reduced in size and increased in strength.
43. The apparatus as claimed in claim 42 wherein:
- said connector is reduced in size by about fifty percent.
44. The apparatus as claimed in claim 42 wherein:
- a plurality of said reduced sized connectors have a high density when packaged for use.
45. An insulation displacement connector comprising:
- an electrically conductive body having a first portion and a second portion, said body having a slot in said first portion and an egg-shaped aperture in said second portion.
46. The apparatus as claimed in claim 45 wherein:
- said egg-shaped aperture having a larger end and a smaller end, said aperture being disposed with said larger end opening to said slot.
47. An insulation displacement connector comprising:
- an electrically conductive body having a first portion and a second portion, said body having a slot in said first portion and an oviform shaped aperture in said second portion.
48. The apparatus as claimed in claim 47 wherein:
- said oviform shaped aperture includes a broader end, said broader end being disposed adjacent said slot.
49. An insulation displacement connector comprising:
- a thin metal strip formed to have two legs, a base and an opening between said legs and above said base, said opening including an upper elongated slot portion with parallel sides and a lower egg shaped portion.
50. An insulation displacement connector comprising:
- a thin metal strip formed to have two legs, a base and an opening between said legs and above said base, said opening having an enlarged lower portion and an elongated slot upper portion, said opening lower portion including a lower rounded part, a curved diverging part above said lower rounded part and a curved converging part above said curved diverging part and beneath said elongated slot upper portion, said curved diverging part and said curved converging part formed of changing radii.
51. An insulation displacement connector comprising:
- a thin metal strip formed to have two legs, a base and an opening between said legs and above said base, said opening having an enlarged lower portion and an elongated slot upper portion, said lower portion of said opening having a lower part surrounded by curved walls having smaller radii, a middle part surrounded by walls having larger radii and a top part surrounded by walls having radii larger than said walls with smaller radii and smaller than said walls with larger radii.
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Type: Grant
Filed: Apr 12, 2000
Date of Patent: Mar 15, 2005
Assignee: Emerson Network Power, Energy Systems, North America, Inc. (St. Louis, MO)
Inventor: Jane X. Lee (Bloomingdale, IL)
Primary Examiner: Lincoln Donovan
Attorney: Harness, Dickey & Pierce, P.L.C.
Application Number: 09/548,038